Electrical cord connection covering techniques

ABSTRACT

An electrical connection covering apparatus is designed to protect from moisture a connection between a plug of one extension cord and a socket of another extension cord. A compressible and elastic diaphragm is used to form a seal around the cables of the extension cords where they enter the apparatus. The apparatus includes a housing that has at least one aperture. The diaphragm extends across the aperture. The diaphragm projects inwardly with respect to an interior surface of the housing. The compressibility and elasticity of the diaphragm material is greater than that of the housing material.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/703,274, filed on May 4, 2015, the entirety of which is hereinincorporated by reference.

BACKGROUND

Generally speaking, this application discloses techniques relating toweatherproofing plug connections for electrical cords, such as extensioncords or decorative lighting cords.

It may be desirable to keep moisture from interfering with electricalcord plug connections. If such a connection is corrupted by moisture,short circuits to ground may occur causing a potentially dangerouscondition or causing circuit breakers, fuses, or ground-fault interruptprotection circuits to prevent the flow of current through theelectrical cord. For example, outdoor holiday lighting often involvesthe use of multiple plug connections in an environment with unfavorableenvironmental conditions (for example, snow, melting snow, fog, sleet,freezing rain, rain, extreme temperatures, salt, etc.). Thus, it isdesirable to have an apparatus that covers a plug connection that issubstantially sealed to prevent corruption of the plug connection bymoisture.

SUMMARY

According to certain inventive techniques, an electrical connectioncovering apparatus has a housing portion including a housing material,an exterior surface, an interior surface, and a first diaphragmaperture. The apparatus also has a first diaphragm including a diaphragmmaterial that extends across the first diaphragm aperture and projectsinwardly with respect to the interior surface of the housing portion.The compressibility and elasticity of the diaphragm material is greaterthan that of the housing material.

The first diaphragm includes an interior surface, an exterior surface,and may have a recess projecting outwardly with respect to the interiorsurface of the first diaphragm. The recess may be shaped like ahalf-funnel and may have one or more inwardly projecting ribs.

The housing portion may have a second diaphragm aperture and theapparatus may further include a second diaphragm extending across thesecond diaphragm aperture and projecting inwardly with respect to theinterior surface of the housing portion. The second diaphragm mayinclude the same material as the first diaphragm. The second diaphragmmay also have an outwardly projecting recess. This recess may also beshaped like a half-funnel and may have one or more inwardly projectingribs.

According to certain inventive techniques, an electrical connectioncovering apparatus covers a connection of a first electrical cordincluding a plug and a cable with a second electrical cord including asocket and a cable. The apparatus includes two housing portions and fourdiaphragms. The housing portions include a housing material and thediaphragms include a diaphragm material. Each housing portion includesan interior surface, an exterior surface, a first end having a recessprojecting outwardly from the interior surface, a second end having arecess projecting outwardly from the interior surface, a first diaphragmaperture proximate the first end, and a second diaphragm apertureproximate the second end. The four diaphragms extend across the fourdiaphragm apertures, respectively. The diaphragms project inwardly fromthe corresponding interior surface of the housing portions. The firstdiaphragm and the third diaphragm may oppose, or preferably contact,each other when the first housing portion is mated with the secondhousing portion. The second diaphragm and the fourth diaphragm mayoppose, or preferably contact, each other when the first housing portionis mated with the second housing portion. The recess of the first end ofthe first housing portion and the recess of the first end of the secondhousing portion form together a receiving area to accommodate the firstcord when the first housing portion is mated with the second housingportion. The recess of the second end of the first housing portion andthe recess of the second end of the second housing portion form togethera receiving area to accommodate the second cord when the first housingportion is mated with the second housing portion. The compressibilityand elasticity of the diaphragm material is greater than that of thehousing material.

Each of the diaphragms may include an outwardly projecting recess. Therecess may have a half-funnel shape. When the housing portions aremated, the recesses of the first diaphragm and the third diaphragm formtogether a funnel shape and the recesses of the second diaphragm and thefourth diaphragm form together a funnel shape. The apparatus may alsoinclude elongated sealing portions that are located alongside the rimsof the two housing portions. The elongated sealing portions may contacteach other when the housing portions are mated. The sealing portions mayinclude the diaphragm material. One sealing portion may be integratedwith the first diaphragm and the second diaphragm. The other sealingportion may be integrated with the third diaphragm and the fourthdiaphragm. The two housing portions may be clamshell portions. Theapparatus may also include two strain relief portions.

According to certain inventive techniques, a method of manufacturingelectrical cord covering apparatus includes: injecting a first materialinto a mold; cooling the first material to a hardened state to form ahousing including a plurality of diaphragm apertures; transferring thehardened first material to a second mold; injecting a second materialinto the second mold; cooling the second material to form a plurality ofdiaphragms attached to the housing and covering corresponding ones ofthe plurality of diaphragm apertures. The compressibility and elasticityof the second material is greater than that of the first material.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 illustrates a perspective view of an electrical connectioncovering apparatus in a closed position, according to certain inventivetechniques.

FIG. 2 illustrates a top view of the electrical connection coveringapparatus in the closed position.

FIG. 3 illustrates a bottom view of the electrical connection coveringapparatus in the closed position.

FIG. 4 illustrates a right-side view of the electrical connectioncovering apparatus in the closed position.

FIG. 5 illustrates a left-side view of the electrical connectioncovering apparatus in the closed position.

FIG. 6 illustrates a rear view of the electrical connection coveringapparatus in the closed position.

FIG. 7 illustrates a front view of the electrical connection coveringapparatus in the closed position.

FIG. 8 illustrates a perspective view of the electrical connectioncovering apparatus in an open position.

FIG. 9 illustrates a perspective view of the electrical connectioncovering apparatus in the open position with a portion of a firstelectrical cord and a portion of a second electrical cord.

FIG. 10 shows a flowchart for a method of manufacturing an electricalconnection covering apparatus, such as the one illustrated in FIGS. 1-9,according to certain inventive techniques.

FIGS. 11A and 11B show a cross-sectional view of a diaphragmillustrating its staircase profile, according to certain inventivetechniques.

The foregoing summary, as well as the following detailed description ofcertain techniques of the present invention, will be better understoodwhen read in conjunction with the appended drawings. For the purposes ofillustration, certain techniques are shown in the drawings. It should beunderstood, however, that the claims are not limited to the arrangementsand instrumentality shown in the attached drawings. Furthermore, theappearance shown in the drawings is one of many ornamental appearancesthat can be employed to achieve the stated functions of the system.

DETAILED DESCRIPTION OF THE APPLICATION

FIGS. 1-8 show different views an apparatus 100 for covering anelectrical connection between two cords, according to certain inventivetechniques. FIGS. 1-7 show different views the apparatus 100 in a closedposition and FIG. 8 shows the apparatus 100 in an open position. FIG. 9also shows the apparatus 100 in an open position with connectedelectrical cords.

The apparatus 100 is intended to protect a plug/socket connectionbetween electrical cords (e.g., extension cords). The apparatus 100 mayinclude two housing portions 110, 120 that can be opened and closed. Forexample, the housing portions 110, 120 may be clamshell parts and theymay be connected by a hinge 140 (such as a living hinge). When theapparatus 100 is in an open position (i.e., the housing portions 110,120 are not fully engaged or mated), a plug/socket connection betweenelectrical cords may be positioned as shown in FIG. 9. The housingportions 110, 120 may then be closed to form an enclosure that protectsthe connection from undesirable substances (e.g., water or salt).

There are two types of seals that are sealed by the enclosure. The firsttype of seal is around the edges of each housing portion 110, 120. Thesecond type of seal is at the apertures in the ends of the apparatus100, where the cables of the cords enter and exit the enclosure. Theinventive techniques disclosed herein create effective seals to protectthe plug connection.

The housing portions 110, 120 may be made of, or include a material suchas plastic (e.g., polyethylene, polypropylene, ABS, polycarbonate,nylon, or the like) or metal. The material may be substantially rigid,and may have a relatively low compressibility and elasticity, such asthose defined by the material data sheets available for theabove-referenced plastic materials.

The material that forms the seals or is included in the seals (anddiaphragms as discussed below) may be a thermoplastic elastomer. Otheroptions could include silicone, rubber, ballistic gel, or the like. Thismaterial may be more compressible and more elastic than theaforementioned housing material.

The housing portions 110, 120, when mated or engaged, may form an innerhollow region that may be generally tube-shaped and may have a maximumradius. On each side of the tube, lateral regions may taper down to aradius that is smaller than the maximum radius of the inner hollowregion. These lateral regions may be frustoconical. At the ends of theselateral regions, there are apertures where cables of the cordsenter/exit the central region formed by the housing portions 110, 120 inthe closed position. As will be discussed, diaphragms are employed tomake seals around the cords at these apertures, thereby inhibiting thepenetration of contaminants (e.g., water or moisture) into the innerhollow region of the enclosure.

For reference, each housing portion 110, 120 may have an interiorsurface that faces the interior hollow region of the enclosure and anexterior surface that faces outwardly from the enclosure. At each end ofthe housing portion 110 (e.g., right-side end and left-side end), theremay be a recess 115. Each recess 115 may project outwardly from theinterior surface of the housing portion 110. Each recess 115 may bearcuate. Similarly, at each end of the housing portion 120 (e.g.,right-side end and left-side end), there may be a recess 125. Eachrecess 125 may project outwardly from the interior surface of thehousing portion 120. Each recess 125 may be arcuate. When the housingportions 110, 120 are mated or engaged, the recesses 115, 125 togethermay form apertures in the ends of the apparatus 100. These apertures maybe the ones through which the cables enter/exit the interior hollowregion of the apparatus 100.

The housing portion 110 may include an aperture 111 proximate to one endof the housing portion 110 (e.g., the left-side end as depicted in FIGS.1 and 2). The housing portion 110 may further include an aperture 112proximate to the opposite end of the housing portion 110 (e.g., theright-side end as depicted in FIGS. 1 and 2). Similarly, the housingportion 120 may include an aperture 121 proximate to one end of thehousing portion 120 (e.g., the left-side end as depicted in FIGS. 1 and2). The housing portion 120 may further include an aperture 122proximate to the opposite end of the housing portion 120 (e.g., theright-side end as depicted in FIGS. 1 and 2). The apertures 111, 112,121, 122 may be referred to as diaphragm apertures for reasons that willbecome apparent from the discussion below.

A plurality of diaphragms 131, 132, 133, 134 extend across respectiveapertures 111, 112, 121, 122. The diaphragms 131, 132, 133, 134 may eachinclude a material that is more elastic and compressible than a materialused for the housing. The properties of elasticity and compressibilityof the diaphragms 131, 132, 133, 134 assist to form a seal around theelectrical cables that enter and exit the internal hollow region of theapparatus 100.

Edges of the diaphragms 131, 132 may optionally be connected or adheredto the housing portion 110 (e.g., the interior surface of the housingportion 110). Similarly, edges of the diaphragms 133, 134 may beconnected to the housing portion 120 (e.g., the interior surface of thehousing portion 120). For example, the edges of the diaphragms 131, 132,133, 134 may be adhered to the housing portions 110, 120 through anover-molding process. A thermal bond may be used (e.g., ultrasonicbonding or friction welding). Channels, grooves, or other irregularitiesin the housing portions 110, 120 may be used to improve adherence of thediaphragms 131, 132, 133, 134 to the housing portions 110, 120 duringthe over-molding process. Instead of thermal bonding, glues or epoxiesmay be used.

The diaphragms 131, 132, 133, 134 may each project inwardly from theinterior surface of the respective housing portions 110, 120 towards orinto the interior hollow region. For example, as depicted in FIGS. 1-9,the diaphragms 131, 132, 133, 134 each include a sloped area 137 thatextends inwardly and a horizontal area 138 that extends along ahorizontal plane of the apparatus 100. The horizontal area 138 may bepositioned at the bottom of the sloped area 137. The sloped area 137permits the diaphragms to project inwardly towards or into the interiorhollow region from the interior surface of the respective housingportions 110, 120. The inward projection of the sloped area 137 providesinward pressure on a cable when the apparatus 100 is in a closedposition. The inward pressure of the diaphragms assists in forming aseal around the electrical cables that enter and exit the interior ofapparatus 100.

Abutting the horizontal area 138, the diaphragm includes a recess 139projecting outwardly away from the interior of the apparatus 100 (i.e.,projecting outwardly with respect to the interior surface of thediaphragm).

As depicted, the recess 139 may be shaped like half of a funnel. Therecess 139 may have a staircase profile, as illustrated in FIGS. 11A and11B. By “funnel” or “half-funnel” it should be understood that therecess 139 may have a staircase profile and still form a half-funnelshape. Different levels on the staircase profile may have radiuses toaccommodate different cable sizes, respectively. Alternatively, therecess 139 may have a profile with continuously varying radiuses (i.e.,smoothly varying and not a staircase profile). The recess 139 may haveany suitable profile—e.g., rectangular, triangular, ovate, etc.According to one technique, the horizontal area 138 does not have arecess 139.

When the housing portions 110, 120 are mated or fully engaged with eachother, the diaphragms 131, 133 may oppose each other, or contact eachother. Similarly, the diaphragms 132, 134 may also oppose each other, orcontact each other. In the example illustrated in FIGS. 1-9, thehorizontal areas 138 of the respective diaphragms contact each other.The contact between the diaphragms 131, 133 and 132, 134 may assist informing a seal around the electrical cables that enter and exit thehollow interior region of the apparatus 100. It should be understood,however, that the diaphragms 131, 133 and 132, 134 may still assist toform seals even if they do not necessarily form a contact between eachother when the apparatus 100 is in a closed position.

The recesses 139 of the diaphragms 131, 133 may together form areceiving area to accommodate a cable of an electrical cord. The twohalf-funnel recesses 139 of diaphragms 131, 133 may form together afunnel-shaped receiving area. The recesses 139 of the diaphragms 132,134 may also form together a receiving area to accommodate a cable ofanother electrical cord. Again, the two half-funnel recesses 139 ofdiaphragms 132, 134 may form together a funnel-shaped receiving area.The receiving areas may have other shapes, such as a tube-like shape. Inthe case when the recesses 139 have a staircase profile, as illustratedin FIG. 11, the receiving area may resemble a terraced wedding cake withthe terraces or levels having diminishing radiuses. When the recesses139 of the diaphragms form a staircase profile, the receiving area mayhave different levels, each sized to receive a different sized cable.

When the receiving area formed by the recesses 139 of the diaphragms131, 133 accommodates a cable of an electrical cord, the diaphragms 131,133 may stretch around the cable and compress against the cable. Whenthe receiving area formed by the recesses 139 of the diaphragms 132, 134accommodates a cable of an electrical cord, the diaphragms 132, 134 maystretch around the cable and compress against the cable. The elasticityand compression properties of the diaphragms 131, 133 assist in forminga seal around each cable.

According to the technique by which the horizontal area 138 does nothave a recess, the diaphragms 131, 133 may still stretch around thecable and compress against the cable. It may be possible to have onediaphragm with a recess and one without (i.e., flat). It may also bepossible to have a diaphragm with an outwardly projecting region (i.e.,projecting outwardly rather than recessing inwardly). The principle ofoperation remains the same.

As illustrated in FIGS. 1-9, the apparatus 100 is also configured toform seals in an area around the edges of the housing portions 110, 120when the housing portions 110, 120 are mated or engaged.

The housing portion 110 may have a rim around its edges. A first sealingportion 135 may be arranged around the rim of housing portion 110. Thehousing portion 120 may have a rim around its edges. A second sealingportion 136 may be arranged around the rim of housing portion 120. Thesealing portions 135 and 136 may be elongate and extend along the rimsof the housing portions 110, 120. The sealing portions 135 and 136 maynot cover the outermost edges of the rims of the housing portions 110,120. The sealing portions 135 and 136 may include the diaphragmmaterial. The first sealing portion 135 may be integrated with thediaphragms 131 and 132 and the second sealing portion 136 may beintegrated with the diaphragms 133 and 134.

When the housing portions 110, 120 are closed or mated to form anenclosure, the sealing portions 135 and 136 may contact each other.Contact between the sealing portions 135 and 136 assists in providing aneffective seal around the rims of the housing portions 110, 120.

The apparatus 110 may be removably securable (e.g., capable of beingengaged or mated) when in the closed position. For example, theapparatus 100 may include locking features 113, 123 and 114, 124. Thelocking features 113 and 114 may be part of the first housing portion110, and the locking features 123 and 124 may be part of the secondhousing portion 120, or vice versa. The locking features 113, 123 maylockably mate with each other. The locking features 113, 123 may be snaplocking features. The locking features 114, 124 may be configured toaccommodate a lock, tie, or some other locking mechanism to secure theapparatus 100 in a closed position. The locking mechanisms 113, 123,114, and 124 may be centrally located (as depicted in FIGS. 1-9) or maybe located towards the ends of the housing portions 110, 120. There maybe two, three, or more sets of the locking features 113, 123 and 114,124. For example, there may be one set in the middle and one set on eachof the ends of the housing portions 110, 120.

The apparatus 100 may also include one or more strain relief portions126. The strain relief portions 126 may be a part of or integrated withthe first housing portion 110 and/or the second housing portion 120. Thestrain relief portions 126 may be hook shaped (as depicted in FIGS. 1-3and 8-9), and may project from the front or rear ends of the housingportions 110, 120. Alternatively, the strain relief portions 126 mayproject from the primary axial ends of the first or second housingportions 110, 120. Other arrangements of the strain relief portion(s)126 may be possible. When the electrical cords forming a plug/socketconnection are placed in the interior hollow region of the apparatus 100formed by the housing portions 110, 120, the cables of the cords may befed underneath, through, and/or around the strain relief portions 126.The strain relief portions 126 may relieve tension at the plug/socketconnection, thereby preventing the connection from being inadvertentlyor improperly pulled apart.

FIG. 10 shows a flowchart 1000 for a method of manufacturing anelectrical connection covering apparatus, such as the apparatus 100illustrated in FIGS. 1-9, according to certain inventive techniques.According to the flowchart 1000, a housing material is injected into afirst mold at step 1010. The first mold is configured to allow thehousing material to form a housing including a plurality of diaphragmapertures. At step 1020, the housing material in the first mold isallowed to cool to a hardened state to form the housing including aplurality of diaphragm apertures. The hardened housing is thentransferred to a second mold at step 1030. The second mold is configuredto allow a diaphragm material to attach to the housing and cover theplurality of diaphragm apertures. A diaphragm material with acompressibility and elasticity that is greater than the housing materialis selected, and, at step 1040, is injected into the second mold. Atstep 1050, the diaphragm material is then cooled to form a plurality ofdiaphragms attached to the housing material and covering the pluralityof diaphragm apertures.

While the invention has been described with reference to certaintechniques, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted withoutdeparting from the scope of the invention. In addition, manymodifications may be made to adapt a particular situation or material tothe teachings of the invention without departing from its scope. Forexample, the techniques described in the present application may beapplicable not only to protecting electrical connections, but may alsobe useful for plumbing or other applications (e.g., medicalapplications). For example, the diaphragms may be used to create sealsthat inhibit the flow of fluids in any application. The seals may beuseful for keeping fluids from flowing out of the housing as well asinto the housing. Such an arrangement may be used to remedy, forexample, a hole in a pipe or other plumbing whereby the seals formedaccording to the inventive techniques prevent the unrestrained flow offluids. Therefore, it is intended that the invention not be limited tothe particular technique disclosed, but that the invention will includeall techniques falling within the scope of the appended claims.

1. An apparatus for receiving an electrical cable, the apparatuscomprising: a first housing portion including a housing material, anexterior surface, an interior surface, and a first diaphragm aperture; asecond housing portion configured to mate with the first housingportion, wherein a receiving aperture configured to receive theelectrical cable is formed only when the first and second housingportions are mated; ballistic gel configured to form a seal around theelectrical cable when the first and second housing portions are mated; afirst diaphragm that extends across the first diaphragm aperture; andwherein: the first diaphragm aperture exists when the first housingportion is not mated with the second housing portion and when the firsthousing portion is mated with the second housing portion; and the firstdiaphragm aperture is separate from the receiving aperture.
 2. Theapparatus of claim 1, further comprising: a first elongated sealingportion located alongside a rim of the first housing portion; a secondelongated sealing portion located alongside a rim of the second housingportion; and wherein the first elongated sealing portion and the secondelongated sealing portion contact each other when the first housingportion is mated to the second portion.
 3. The apparatus of claim 2,wherein the first elongated sealing portion and the second elongatedsealing portion each comprise ballistic gel.
 4. The apparatus of claim1, wherein: the first housing portion comprises a clamshell portion; andthe second housing portion comprises a clamshell portion.
 5. Theapparatus of claim 1, further comprising: a first strain relief portionextending away from and included as part of either of the first housingportion and the second housing portion; and a second strain reliefportion extending away from and included as part of either of the firsthousing portion and the second housing portion.